CVNG 0001 - Advanced Reliability Practices for Improving Manufacturing Equipment Performance
Course Description
This two-day professional development course is designed to help manufacturing professionals overcome the limitations of traditional reliability practices and adopt innovative approaches that drive significant improvements in equipment performance and operational efficiency.
Many organizations continue to rely on outdated approaches like basic root cause analysis, brainstorming for causes and solutions and using MTBF as the primary metric for reliability. These methods often fall short of driving the innovations required to keep pace with the demands of modern manufacturing.
This program introduces a new paradigm. For example, instead of only focusing on maintenance, monitoring and better operator training, the goal is failure elimination with elegant solutions — solutions that are inexpensive, simple and without trade-offs. Doing analysis that does not lead to or support elegant solutions can be a waste of time. This approach is about being purpose-driven and solution-oriented.
This course includes some familiar tools & methods, such as reliability apportionment and modeling, data analysis with Weibull Analysis and several different testing approaches.
However, this class also includes several novel tools and methods that aren’t widely used, even though they are well-proven. By definition, this represents a clear competitive advantage for anyone who goes after it. These elements include Science-Based Causal Analysis, TRIZ, Cognitive Behavioral Analysis and the use of various AI tools.
Through engaging discussions, real-world case studies and practical frameworks, you will gain actionable insights into how these advanced methods can be implemented to reduce downtime, optimize performance and enhance overall equipment reliability.
Course Outline/Topics
Section 1: Setting Performance/Reliability Goals
- Why this is so important
- Reliability apportionment
- Reliability block diagram
- Total cost & what if?
- How AI can help
Section 2: Data Collection & Analysis
- Why this is so important?
- “MTBF” vs. “Probability of Failure”
- Failures, failure modes & wear factors
- Weibull analysis
- How AI can help
Section 3: Science-Based Causal Analysis (SBCA)
- Shortcomings of using standard tools for serious problems
- Everything is driven by science, equations and research
- Cognitive-behavior analysis
- The goal is to identify the causes in a precise way, to set the stage for their elimination
- How AI can help
Section 4: Systematic Solution Generation
- Introduction to TRIZ (Theory of Inventive Problem Solving)
- Start with the causes & contradictions identified during the SBCA to identify physical contradictions
- Value of elegant solutions
- Identify many elegant solutions for each cause by using the separation strategies from TRIZ
- How AI can help
Section 5: Reliability Testing
- Reliability Qualification Tests, Sequential Probability Ratio Tests, Growth Testing and others
- Assumptions and problems with standard testing methods to get statistically-valid results
- Understand the value of collecting and analyzing the right data
- Weibull-based Testing plans
- How AI can help
Benefits and Learning Outcomes
By the end of this program, participants will be equipped with forward-thinking strategies and tools to drive sustainable improvements in manufacturing reliability and position their organizations for long-term success.
- Identify the real goals for manufacturing engineers, maintenance teams and equipment designers in improving reliability.
- Explain the overall process for enhancing manufacturing reliability and the foundational skills associated with existing methods.
- Demonstrate awareness of a disciplined, rigorous, science-based approach to solving complex problems, including the use of TRIZ and its powerful “separation strategies” for addressing physical contradictions.
- Examine how Cognitive-Behavioral Analysis can uncover the human factors contributing to failures.
- Assess the potential of AI to enhance your ability to implement the methods introduced, improving problem-solving and reliability outcomes.
- Develop a personalized plan to pursue additional training tailored to your specific needs and career objectives.
Who Should Attend
This course is tailored for reliability engineers, maintenance managers and other manufacturing professionals seeking to break free from traditional constraints and lead transformative change within their organizations.
These groups would benefit most from this training:
- Manufacturing Engineers, Maintenance and other technical persons would use/perform the methods included in their training.
- Managers and other leaders of those people engaged in performing the various methods, including those who would direct the training, use and review the efforts and results.
- The suppliers/manufacturers/designers of the equipment.
Partners & Professional Credits
- Professional Development Hours 14.0 PDHs